AGI RT 03 Revision 3

Document is uncontrolled when printed RT 03 Revision 3

AGI RT 03 REVISION 3

JULY 2012

RADIOGRAPHIC INSPECTION

FOR CSA Z662 PIPELINE WELDS

ACUREN APPROVAL

POSITION NAME SIGNATURE

Corporate Level III B. Nightscales

Director of Quality T. Kruger

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RT 03 REVISION 3 RADIOGRAPHIC INSPECTION

July 2012

CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 PERSONNEL QUALIFICATION AND RESPONSIBILITIES

4.0 SAFETY

5.0 EQUIPMENT AND MATERIALS

6.0 INSPECTION

7.0 ACCEPTANCE CRITERIA

8.0 REPORT

APPENDIX 1 – TECHNIQUES

APPENDIX 2 – FILM PROCESSING

APPENDIX 3 – EXAMPLE TECHNIQUE QUALIFICATION SHEET

Revision Summary R1- December 2011 References -revised CSA Z662 - 11 Language was modified throughout to improve clarity and ensure compliance to the standard Revision Summary R2- March 2012 Revisions to 6.1.2.1 Spelling, wording Revisions to 6.3 Lead numbers for weld identification Revision Summary R3- July 2012 Revision to 5.2 Spelling Revision to 6.3 f) Changed to ‘D” for delay Added 6.3 g) Verification identification designation Added Appendix 3 Example technique qualification sheet 6.5 to 7.0 Corrected bullet numbering

AGI RT 03 REVISION 3 Radiographic Inspection for CSA Z662 Pipeline Welds

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1.0 SCOPE

This procedure describes the requirements to be followed by Acuren Group Inc. (AGI) technicians when performing radiographic inspection in accordance with CSA Z662, using either x-ray or gamma radiography exposure devices with film imaging media. It is applicable to piping of commercially available materials and thicknesses for diameters to 48”.

2.0 REFERENCES

a. Acuren Calibration Manual – CAL D01

b. Acuren Code Extract Manual

c. Acuren Radiation Safety Management System

d. Acuren Safety Management System

e. CSA Z662-11

3.0 PERSONNEL QUALIFICATION AND RESPONSIBILITIES

Radiography shall be carried out by personnel certified to CAN/CGSB-48.9712 with the responsibilities listed below. Exposure Device Operators and other noncertified personnel may be used.

a. An RT Level I, II or III technician or a CEDO must perform radiographic inspections as per the AGI RSMS.

b. An RT Level II or III technician shall carry out final interpretation and sign the report.

c. An RT Level III technician shall approve new or revised techniques and procedures.

d. An RT Level II will be allowed to determine and document job-specific RT techniques. New or revised RT techniques must be reviewed and approved by the RT Level III.

4.0 SAFETY

AGI personnel shall meet the requirement of the AGI Radiation Safety Management System as nuclear energy workers and shall follow all requirements of that system when performing radiography. In addition, all personnel shall follow AGI's Safety Management System. All personnel carrying out radiographic inspections, are responsible for the safety of others working near the area of radiation. Protection and monitoring shall comply with government and CNSC and Health Canada requirements.



5.0 EQUIPMENT AND MATERIALS

5.1 Radiation Energy

5.1.1 Types

The energy source may be either X-ray or radioisotopes that can achieve the density and IQI sensitivity requirements of CSA Z662 or the client.

5.1.2 Source (Focal Spot) Size

Physical source size varies with the isotope type and strength. Maximum isotope dimensions are 3.5mm for Selenium, 5.0mm for Iridium 192 and 7.0mm for Cobalt 60. The size is provided on the manufacturer decay charts that accompany the source. Focal spot varies with each x-ray generator.

5.2 Radiographic Film

AGI uses Agfa or Kodak or Fuji industrial radiographic film as listed below. Alternate types or alternate manufacturers may be used with approval of a Level III. Type and size are dependent upon application and may vary but density and sensitivity requirements must be met.

FILM TYPES

Agfa Class* Kodak Class* Fuji Class*

Structurix D2 Special DR50

Structurix D3 I M100 I IX 50 I

Structurix D4 I MX125

Structurix D5 I T200 I IX 80 I

Structurix D7 II AA400 II IX 100 II

*Refers to the manufacturers supplied class rating of the film per ASTM E1815.

Film shall be of such length and width to allow sufficient coverage of the weld so that two reference marker locations are common to two successive images.

5.3 Radiographic Screens

Lead or lead foil screens must be used. Typical configuration is either lead 0.127mm (0.005") or 0.254mm (0.010") front and 0.254mm (0.010") back. Pre-packaged film used for x-ray is supplied with lead foil 0.025 mm (0.001”) front and back. Screens shall be free of dirt, oxidization and surface anomalies.



5.4 Image Quality Indicators (IQI)

The image of an IQI shall be clearly defined and only hole type IQI's meeting the requirements of ASTM E1025 or wire type IQI’s meeting the requirements of ASTM E747 or ISO 19232-1 are to be used as shown in the ASME tables below:



5.5 Viewing Facilities

a. An industrial radiographic viewer with a variable light source shall be used. It shall provide sufficient intensity to allow for interpretation of the radiograph and to ensure that the essential IQI hole or wire is visible during evaluation.

b. If required, the viewer shall have masks to prevent light from low-density areas or from the outside edge of the radiograph from interfering with interpretation.

c. Viewing shall take place in an area with subdued background lighting of an intensity that will not cause reflections, shadows, or glare on the radiograph such that it will interfere with interpretation.

5.6 Undercut Comparator Shims

Undercut comparator shims shall be made out of radiographically similar to the material being inspected and the image of at least one shall appear on each radiograph.



5.7 Densitometers and Step Wedge Comparators

Density of the radiograph shall be determined using either a step wedge (density strip) that has been verified within the previous 12 months or a densitometer.

5.7.1 Step wedge comparison strips must have a minimum of five steps with densities from at least 1.0 to 4.0. It may be purchased with verification to a national standard by the manufacturer. Alternatively it may be verified with a calibrated densitometer. When verified with a densitometer the step wedge film is acceptable if the density readings do not vary by more than +/- 0.1 density units from the calibrated strip.

5.7.2 When densitometers are used they must be checked against the calibrated density strip at the beginning of each shift or change of apertures. Allow the densitometer to warm up for five minutes. Zero the instrument. Take four readings at the control strip densities nearest to 1.0, 2.0, 3.0 and 4.0. Results must be +/- 0.05. Results of this verification need not be recorded.

Densitometers shall be calibrated every 90 days in accordance with AGI CAL D01.

5.8 Documentation

Each technician shall be provided with or have available at the workplace: a copy of this procedure, the current AGI Code Extract Manual, an AGI supplied report form and a copy of a work order or call sheet where applicable (see 6.0).

6.0 INSPECTION

Client information and specific inspection requirements including acceptance criteria shall be provided to the technician in the form of a Work Order (Call Sheet) prior to the start of examination.

6.1. Radiographic Technique

Whenever practical, a single-wall exposure technique shall be used. When there is no reasonable access to the inside diameter of the pipe, a double-wall technique shall be used. Technique numbers referred to are located in Appendix 1.

6.1.1 Single-Wall Techniques with Single Wall Viewing (Technique 1, 2 and 3)

The radiation passes through only one wall of the weld or material and that wall is viewed.

6.1.2 Double Wall Techniques

When configuration does not allow a single wall technique a double wall technique is required.



6.1.2.1 Double-Wall with Single Wall Viewing (Technique 4)

The following chart lists the minimum number of exposures that are to be used to obtain sufficient weld coverage under normal circumstances. Additional exposures may be required when thickness increases to ensure adequate density and sensitivity.

Pipe Diameter Source

Schedule # of Exposures

X-Ray # of Exposures

Gamma

2 to 12 NPS Gamma Less than 100 3 3

2 to 12 NPS Gamma 100 and over 4 4

16 to 18 NPS X-Ray or Gamma All Schedules 4 4

20 NPS X-Ray or Gamma All Schedules 5 5

24 NPS X-Ray or Gamma All Schedules 6 3

30, 36, 42, 48 NPS X-Ray or Gamma All Schedules 4 3

6.1.2.2 Double-Wall Technique with Double Wall Viewing (Technique 6 and 7)

For materials and welds in components 89 mm (3.5 inches) or less in nominal outside diameter, these techniques may be used. The radiation passes through two walls and the weld or material in both walls is viewed. Only source side IQI’s shall be used.

Technique 6 - for welds the radiation beam is offset from the plane of the weld at an angle sufficient to separate the images of the source-side and film-side portions of the weld so that there is no overlap of the areas to be interpreted. When complete coverage is required a minimum of two exposures taken at 90 degrees to each other shall be taken.

Technique 7 – as an alternate for technique 6 the weld may be radiographed with the radiation beam positioned so that the images of both walls are superimposed. When complete coverage is required a minimum of three exposures taken at either 60 or 120 degrees to each other are required.

6.2 Surface Preparation

The surface of welds shall be such that image irregularities cannot mask or be confused with discontinuity images on the radiograph. Where such irregularities are encountered the client shall be informed that rework is required.

6.3 Radiograph Identification

a. It is preferred that radiographic identification appears as a radiographic image using either lead characters, or flash. The weld identification (X1, X2...) shall use lead characters that will appear as a radiographic image. Where errors or omissions are made, alternate means of permanent marking (indelible marker) are permissible.

b. Minimum identification includes the client name along with unique identifiers such as contract or component and the weld or part number.



c. In the absence of specific client requirements, welds shall be identified with the prefix X (e.g. X1, X2 etc.).

d. Repairs are identified using the original identification with R1, R2 added as applicable.

e. Replacement welds that have been removed or "cut out" shall be marked with the suffix CO. Where two new welds are required due to a cut out, they shall be identified as CO-A (upstream side) and CO-B (downstream side).

f. Where welds are required to be re-shot 24 to 48 hours later when required by the client the second radiograph of the weld shall be identified with a “D” for delay radiograph.

g. Verification radiographs are identified using the original identification followed by the letter V.

6.4 Radiographic Image Identification Markers

6.4.1 Weld Marking

An arrow with a permanent marker will be marked on the downstream side of the weld joint indicating the direction of location markers. Location markers will be placed following the direction of the arrow.

6.4.2 Location Markers

a. Location markers must be placed on the part not on the film cassette.

b. To allow a discontinuity in the weld to be accurately located, location markers shall be lead numbers and must be metric in centimeter increments as per table below:

Pipe Diameter Increments Notes

NPS 2 2 cms 0, 2, 4, 6, 8, 10, 12

NPS 4 3 cms 0, 3, 6, 9, 12, 15, 18,

NPS 3, 6-18 5 cms 0, 5, 10, 15, 20

NPS 20 and over

10 cms There must be a 5 cm marker at the overlap of successive films e.g. 0-35, 35-70, 70-105…

c. Where more than one image is used to inspect a complete circumferential weld, the reference location markers shall be common to two successive images so as to establish that the entire weld length has been covered.



6.5 Image Quality Indicator (IQI) Selection

The thickness on which the IQI is based is the weld thickness plus the approximate weld reinforcement. Reinforcement may be estimated (it need not be measured) but it shall not exceed the maximum permitted by CSA Z662 Table 7.6. Information from that table is provided below:

CSA Z662, Table 7.6 - Outside Crown Height

Nominal Wall Thickness, mm Outside Crown Height Maximum, mm

10 or less 2.5

greater than 10 3.5



6.6 Placement

6.6.1 Where it is not practical to place the IQI on the part or weld, they may be placed on a separate block made of the same or radiographically similar materials.

a) The IQI of the source side of the block shall be placed no closer to the film than the source side of the part.

b) The block shall be placed as close as possible to the part.

c) When hole type IQI's are used the block dimensions shall be large enough to ensure that three sides of the IQI will be visible on the radiograph.

6.6.2 Place a lead letter "F" adjacent to or on the IQI but not masking the essential hole when hole type IQI’s are placed on the film side of the weld.

6.6.3 IQI Placement and Location

a) Hole Type – Placed adjacent to or on the weld. Placement on the weld shall be used only when geometric limitations prevent placement adjacent to the weld.



b) Wire Type – Placed across the weld.

In either case the IQI identification or the lead letter "F", if used, shall not be in the area of interest except where geometric configuration makes it impractical.

For panoramic single-wall exposure techniques, at least three IQI’s shall be spaced equally around the weld circumference. For double-wall exposures, single-wall viewing, IQI’s shall be placed at both ends within 25 mm of the acceptable coverage area for each exposure. For pipe and component welds NPS 4 and less, one IQI may be used at one end of the acceptable coverage area for each exposure. When a weld is repaired, at least one IQI shall be positioned adjacent to each repair area.

6.6.4 When hole type IQ's are selected, shims shall be used to compensate for material thickness greater than the parent metal (within the limits identified in clause 6.5) or to compensate for the total material thickness when the IQI cannot be placed on the material being radiographed.

Shims shall be of radiographically similar material and be of sufficient dimensions such that the outline of at least three sides of the IQI image is visible in the radiograph.

6.6.5 Undercut Comparator Shims

At least three comparator shims shall be used on each panoramic exposure. For all other exposures, one comparator shim shall be used on each film. Comparator shims shall be used to estimate the depth of internal undercut by comparing the density of the image of the internal undercut with the density of images of the known notch depths in the comparator shims.

Comparators shall not be used for the purpose of shim material to compensate for weld crown.

6.7 Direction of Radiation

The central beam of radiation should be centred on the area of interest whenever practical.

6.8 Film Processing

Film processing is normally manual. Where automatic processors are used a local procedure based upon the manufacturers requirements shall be in place.

Guideline for manual film processing is included in Appendix 2.

6.9 Film Density

Film density, measured through the area of interest shall be 2.0 to 4.0 for both gamma and x-ray. Due to variations in weld irregularities, small localized areas will be acceptable at a minimum density of 1.5.

The unexposed base density of film shall not exceed 0.30.



6.10 Geometric Relationship

The film shall be placed as close to the surface of the weld being inspected as possible. The distance between the source of radiation and the film shall not be less than seven times the distance between the film and the opposite side of the weld being examined. The source of radiation shall not be offset by more than five degrees from the plane of circumferential welds except for elliptical projections, where the offset can be increased to ensure proper separation of the opposing weld sides.

6.11 Film Quality

Radiographs shall be free from false indications, mechanical, chemical, or other blemishes to the extent that they will not mask or be confused with the image of any discontinuity in the area of interest. Appendix 2 provides detailed guidelines for the proper manual processing of radiographic film.

6.12 IQ1 Sensitivity

6.12.1 Sensitivity is defined as the ability to be able to clearly see the essential hole or wire of the IQI used per clause 6.5.

6.12.2 The radiograph shall display the IQI identifying numbers and letters.

7.0 ACCEPTANCE CRITERIA

The radiographs shall be interpreted in accordance with the Standards of Acceptance in Section 7.11 in CSA Z662 or in additional sections as specified by the client i.e. “sour service”. These are provided to technicians in the form of the AGI Code Extract manual. Specific client requirement in addition to CSA Z662 shall be provided to AGI personnel prior to mobilization.



8.0 RADIOGRAPHIC REPORTING AND RETENTION

Radiographic reports shall include the following fields:

Client Focal Spot/Source Size

Attention Identification

Address Pipe Diameter

Project Material Thickness

Work Location Film Designation

Date Reinforcement Thickness

AGI Job Number Technique

PO/WO SOD (Source to Object Distance)

Procedure OFD (Object to Film Distance

Acceptance Standard Number of Exposures

Material Type Discontinuity Types

Film Brand Discontinuity Location

Radiation Source Accept/Reject

Curies Client Signature

KV Administrative Fields

Screens – Type/Thickness

Number of film per cassette Technician- Signature/Certification

a. Complete all fields. State N/A for not applicable when the field does not apply.

b. Ensure that the acceptance standard field is completed in full, including the standard, relevant clause, date and revision status.

c. Report all material or weld discontinuities and disposition per the acceptance criteria when specified.

Records of the interpretation and the radiographs shall be provided to the client. AGI shall not be responsible for storage of these items after completion of the project.



APPENDIX 1

TECHNIQUE 1 SINGLE WALL TECHNIQUE WITH SINGLE WALL VIEWING (SW-SWV)

Source-Weld-Film Arrangement

TECHNIQUE 2

SINGLE WALL TECHNIQUE WITH SINGLE WALL VIEWING (SW-SWV)



APPENDIX 1

TECHNIQUE 3 SINGLE WALL WITH SINGLE WALL VIEWING (SW-SWV)


The illustration depicts piping but this technique is valid for flat plate

TECHNIQUE 4 DOUBLE WALL WITH SINGLE WALL VIEWING (DW-SWV)

Minimum 3 exposures at 120 degrees




APPENDIX 1

TECHNIQUE 5 DOUBLE WALL WITH SINGLE WALL VIEWING (DW-SWV)

Minimum 3 exposures at 120 degrees


TECHNIQUE 6

DOUBLE WALL TECHNIQUE WITH DOUBLE WALL VIEWING (DW-DWV) Minimum 2 exposures at 90 degrees




APPENDIX 1

TECHNIQUE 7

DOUBLE WALL TECHNIQUE WITH DOUBLE WALL VIEWING (DW-DWV) Minimum 3 exposures at 60 or 120 degrees




APPENDIX 2 MANUAL FILM PROCESSING

Chemistry The requirement for changing chemistry varies due to time, the amount of film being processed, temperature fluctuations, environmental conditions, average film density and others. Change chemistry:

a) whenever film artifacts that could be attributed to exhausted chemistry are present on the radiograph b) if it is over three months old c) when fixer clearing time exceeds 5 minutes d) wash water should be changed weekly as a minimum and more often when in frequent use.

Replenish developer with replenishment solutions and replenish all other chemicals to keep both the level and activity constant. Mixing Chemistry

a) Ensure that the tanks are clean prior to replacing chemistry. b) Mix replacement chemistry as per the directions provided on the packaging. c) Mix replenishment chemistry as per the directions provided on the packaginng. Note that replenishment is

a stronger than original concentration. Addition of original strength developer or fixer does not produce the desired regenerating effect.

Processing Stir the chemistry prior to processing film. Process per standard time and temperature per the attached chart. Developing

a) Do not adjust developing time (“sight develop”) to account for improper exposure times. b) Start development timing as soon as the hanger is placed in the tank. c) Obtain even development by tapping the hanger to dislodge air bubbles then agitate for approximately 15

seconds. Continue to agitate both horizontally and vertically for a few seconds each minute of developing time. Removing the hanger and allowing it to drain from one corner for a few seconds is also recommended.

d) Upon completion of development drain the hanger over the developer tank and place into the stop bath.

Stop Bath a) Immerse and agitate for 30 to 60 seconds. b) Upon completion drain the hanger over the stop tank and place into the fixer.

Fixing

a) Tap and agitate when first immersed and continue agitate for a few seconds each 2 minutes in the fixer solution.

b) Total fixing time is a minimum of twice the clearing time. Maximum time should be 15 minutes. c) Upon completion drain the hanger over the fixer tank and place into the wash.

Washing

a) Ensure that the wash level is sufficient to cover the top bar of the hanger. b) Rinse for a minimum of 30 minutes in fresh wash water.

Drying

a) Place the hangers in a forced air dryer or allow to dry in ambient air.





APPENDIX 3

EXAMPLE TECHNIQUE QUALIFICATION SHEET (Note: Form may vary depending on the applicable Acuren Region)

Documents

AGI RT 03 Revision 3